steering TOYOTA RAV4 2006 Service Service Manual

SP–14SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING
SP
INSTALLATION
HINT:
• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
1. INSTALL FRONT SHOCK ABSORBER WITH COIL
SPRING LH
(a) Install the front shock absorber with coil spring
(upper side) with the 3 nuts.
Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf)
(b) Install the front shock absorber with coil spring to
the steering knuckle with the 2 bolt and 2 nuts.
Torque: 240 N*m (2,447 kgf*cm, 177 ft.*lbf)
NOTICE:
Do not tighten the bolts.
2. CONNECT FRONT STABILIZER LINK ASSEMBLY LH
(See page SP-31)
3. CONNECT FRONT SPEED SENSOR LH (See page
BC-193)
4. INSTALL FRONT WHEEL
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
5. STABILIZE SUSPENSION
(a) Lower the vehicle.
(b) Press down on the vehicle several times to stabilize
the suspension.
6. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust the front wheel alignment (see
page SP-3).
DISPOSAL
1. DISPOSE OF FRONT SHOCK ABSORBER
ASSEMBLY LH
(a) Fully extend the shock absorber piston rod, and
clamp it in a vise at an angle.
(b) Using a drill or similar tool, gradually make a hole in
area A to discharge the gas inside of the absorber.
CAUTION:
As metal debris may be blown outward by the
gas, you must
• Wear protective glasses.
• Cover the area being cut.
NOTICE:
The gas is colorless and harmless.
C127542
C127533
C127546E01

SP–20SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING (for Sport Package)
SP
INSTALLATION
HINT:
• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
1. INSTALL FRONT SHOCK ABSORBER WITH COIL
SPRING
(a) Install the front shock absorber with coil spring
(upper side) with the 3 nuts.
Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf)
(b) Install the front shock absorber with coil spring to
the steering knuckle with the 2 bolt and 2 nuts.
Torque: 240 N*m (2,447 kgf*cm, 177 ft.*lbf)
NOTICE:
Do not tighten the bolts.
2. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
(See page SP-31)
3. INSTALL FRONT SPEED SENSOR LH (See page BC-
193)
4. INSTALL FRONT WHEEL
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
5. STABILIZE SUSPENSION
(a) Lower the vehicle.
(b) Press down on the vehicle several times to stabilize
the suspension.
6. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust the front wheel alignment (see
page SP-3).
DISPOSAL
1. DISPOSE OF FRONT SHOCK ABSORBER
ASSEMBLY LH
(a) Fully extend the shock absorber piston rod, and
clamp it in a vise at an angle.
(b) Using a drill or similar tool, gradually make a hole in
area A to discharge the gas inside of the absorber.
CAUTION:
As metal debris may be blown outward by the
gas, you must.
• Wear protective glasses.
• Cover the area being cut.
NOTICE:
The gas is colorless and harmless.
C127542
C127533
C127546E01

SP–28SUSPENSION – FRONT LOWER BALL JOINT
SP
INSTALLATION
HINT:
• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
1. INSTALL FRONT LOWER BALL JOINT ASSEMBLY
LH
(a) Install the ball joint with the 2 bolts and nut to the
lower arm.
Torque: 92 N*m (938 kgf*cm, 68 ft.*lbf)
(b) Install the lower ball joint with the nut to the steering
knuckle.
Torque: 133 N*m (1,360 kgf*cm, 98 ft.*lbf)
(c) Install a new cotter pin.
If the holes for the cotter pin are not aligned, tighten
the nut further up to 60
.
2. INSTALL STEERING KNUCKLE WITH AXLE HUB
(See page AH-9)
3. CONNECT FRONT SUSPENSION LOWER NO. 1 ARM
SUB-ASSEMBLY LH (See page AH-10)
4. CONNECT TIE ROD END SUB-ASSEMBLY LH (See
page PS-45)
5. INSTALL FRONT DISC (See page BR-43)
6. INSTALL FRONT DISC BRAKE CYLINDER
ASSEMBLY LH (See page BR-46)
7. INSTALL FRONT AXLE HUB NUT (See page AH-10)
8. INSTALL FRONT SPEED SENSOR LH (See page BC-
193)
9. INSTALL FRONT WHEEL
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
10. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust the front wheel alignment (see
page SP-3).

BC–12BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM
BC
(1) Operation description:
The skid control ECU determines the vehicle
condition by receiving signals from the speed
sensor, the yaw rate and deceleration sensor
and the steering sensor. The skid control ECU
controls engine torque with the ECM via CAN
communication and brake fluid pressure through
the pump and solenoid valve. The slip indicator
light blinks and the skid control buzzer sounds
when the system is operating.
for 4WD: The VSC warning light comes on when
the TRC system malfunctions.
for 2WD: The VSC warning light and slip
indicator light come on when the TRC system
malfunctions.
(f) Downhill Assist Control:
When the downhill assist control switch is pressed
with the shift lever on L or R range and the
accelerator and brake pedals not depressed,
downhill assist control is activated. When activated,
4-wheel hydraulic pressure control occurs in order
to maintain a constant low vehicle speed without
causing the wheels to become locked. Thus, the
vehicle can descend a steep hill in a stable manner.
HINT:
• Depressing the accelerator and brake pedal
cancels control of the downhill assist control.
• Downhill assist control begins operating when
driving down on a slope at a speed of 25 km/h
(16 mph) or less with the engine brake applied.

BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEMBC–17
BC
(1) Operation description:
The skid control ECU determines that the
vehicle is in a state in which the AUTO LSD can
operate by using various sensors and switches
to detect the operating conditions of the AUTO
LSD switch, shift position, accelerator pedal, and
brake pedal. When the vehicle is in a state in
which the AUTO LSD can operate, the skid
control ECU effects hydraulic pressure control of
the wheel cylinder at the wheel with the faster
wheel speed so that the wheel speeds of the
right and left drive wheels will become equal.
The slip indicator light blinks and the AUTO LSD
indicator light comes on when the system is
operating. Both the VSC warning light and SLIP
indicator light come on when the AUTO LSD
system malfunctions.
2. COOPERATIVE CONTROL FUNCTION
(a) Description
(1) Braking when Surface Resistance Differs
Between Left and Right Wheels
If the driver suddenly applies the brakes on a
road surface with a considerable difference in
friction coefficient between the right and left
wheels, the difference in the brake force
between the right and left wheels will cause the
vehicle posture to become unstable and create a
yaw movement. In this state, the skid control
ECU controls the VSC to stabilize the vehicle
posture. At the same time, it effects cooperative
control with the EPS to provide steering torque
assist, which facilitates the driver's steering
maneuvers to stabilize the vehicle posture.
(2) Accelerating when Surface Resistance Differs
Between Left and Right Wheels
If the driver suddenly starts off or accelerates on
a road surface with a considerable difference in
friction coefficient between the right and left
wheels, the slippage of a drive wheel will cause
the vehicle posture to become unstable and
negatively affect its acceleration performance. In
this state, the skid control ECU causes the TRC
to control the hydraulic brake of the slipping
drive wheel, and requests the engine ECU to
effect engine output control. At the same time, it
effects cooperative control with the EPS to
provide steering torque assist, which facilitates
the driver's steering maneuvers to stabilize the
vehicle posture.

BC–18BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM
BC
(3) Front Wheel Skid Tendency
When the skid control ECU determines that
there is a front wheel skid tendency, it controls
the VSC to dampen the front wheel skid. At the
same time, it effects cooperative control with the
EPS to provide steering torque assist, which
facilitates the driver's steering maneuvers to
stabilize the vehicle posture. To prevent
excessive steering maneuvers, it provides a
steering torque assist. This assist increases the
resistance to counter the driver's steering effort,
if the driver turns the steering wheel excessively.
(4) Rear Wheel Skid Tendency
When the skid control ECU determines that
there is a rear wheel skid tendency, it controls
the VSC to dampen the rear wheel skid. At the
same time, it effects cooperative control with the
EPS to provide steering torque assist, which
facilitates the driver's steering maneuvers in the
direction to correct the rear wheel skid.
(5) Acceleration During Cornering
A sudden acceleration of the vehicle during
cornering may cause a drive wheel to freewheel,
which could cause the front wheels or rear
wheels to skid. If the skid control ECU
determines that there is freewheeling of a drive
wheel, a front wheel skid tendency, or a rear
wheel skid tendency, it effects cooperative
control with the 4WD system to optimally control
the drive torque distribution to the front and rear
wheels. Furthermore, it controls the TRC and
the VSC as needed to ensure driving stability
and acceleration performance.
(b) Operation
The operation of the solenoid valves under the
cooperative control is the same as the TRC or VSC
operation.
3. ABS WITH EBD, BA, TRC AND VSC OPERATION
(a) The skid control ECU calculates vehicle stability
tendency based on the signals from the 4 wheel
speed sensors, the yaw rate and deceleration
sensor and the steering sensor. In addition, it
evaluates the results of the calculations to
determine whether any control actions (control of
the engine output torque by electronic throttle
control and of the brake fluid pressure by the ABS
and TRACTION actuator) should be implemented.
(b) The slip indicator blinks and the skid control buzzer
sounds to inform the driver that the VSC system is
operating. The slip indicator also blinks when
traction control is operating, and the operation being
performed is displayed.

BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEMBC–19
BC
4. FAIL SAFE FUNCTION
(a) When a failure occurs in the ABS with BA, TRC and
VSC systems, the ABS and VSC warning lights
illuminate, the slip indicator light comes on*1 or
remains off*2, and the operations of those systems
are prohibited. In addition to this, when a failure
which disables the EBD operation occurs, the brake
warning light comes on and its operation is
prohibited.
HINT:
*1: for 2WD
*2: for 4WD
(b) If control is prohibited due to a malfunction during
operation, control is disabled gradually to avoid
sudden vehicle instability.
5. INITIAL CHECK
(a) When the vehicle speed first reaches approximately
6 km/h (4 mph) or more after the ignition switch is
turned ON, each solenoid valve and the motor of the
ABS and TRACTION actuator are sequentially
activated to perform electrical checks. During the
initial check, the operating sound of the solenoid
valve and motor can be heard from the engine
compartment, but this does not indicate a
malfunction.
6. SERVICE MODE
(a) VSC operation can be disabled by operating the
intelligent tester.
HINT:
Refer to the intelligent tester operator's manual for
further details.
7. FUNCTION OF COMPONENTS
Components Functions
Speed Sensor
(Semiconductor Type)Detects the wheel speed and sends the signal to skid
control ECU
Skid Control ECU
(Housed in ABS and TRACTION Actuator)• Processes the signals from each sensor to control the
ABS, BA, TRC, and VSC
• Sends and receives control signals to and from the
ECM, yaw rate and deceleration sensor, steering
sensor, etc. via CAN communication.
ABS and TRACTION Actuator • Consists of the master cylinder cut solenoid valve,
holding solenoid valve, pressure reduction solenoid
valve, pump motor, and reservoir, and adjusts the brake
fluid pressure applied to each wheel cylinder
• Houses the skid control ECU
Solenoid Relay • Supplies power to each solenoid
• Housed in the skid control ECU
Motor Relay (VSC MTR Relay) • Supplies power to the pump motor
• Installed in engine room No. 1 relay block
Fail-safe Relay (VSC FAIL Relay) • Cuts off power to the motor when the pump motor circuit
malfunctions
• Installed in engine room No. 1 relay block

BC–20BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM
BC
HINT:
*1: w/ Downhill assist control
*2: for 2WD w/ AUTO LSD
Steering Sensor • Detects the steering extent and direction and sends
signals to the skid control ECU via CAN communication
• Has a magnetic resistance element which detects the
rotation of the magnet housed in the detection gear in
order to detect the changes in magnetic resistance and
the steering amount and direction
Yaw Rate and Deceleration Sensor • Yaw rate sensor detects the vehicle's angular velocity
(yaw rate) in the vertical direction based on the extent
and direction of the deflection of the piezoelectric
ceramics
• Deceleration sensor measures the capacity of the
condenser that changes the distance between the
electrodes depending on G force, which occurs when
the vehicle is accelerated, and converts the measured
value into electrical signals
• Sends signals to the skid control ECU via CAN
communication
Master Cylinder Pressure Sensor • Detects the brake fluid pressure in the master cylinder
• Housed in the ABS and TRACTION actuator
ECM• Controls the engine output when TRC and VSC are
operating with the skid control ECU via CAN
communication
Downhill Assist Control switch*1 Allows the driver to turn downhill assist control ON and OFF
AUTO LSD switch*2 Allows the driver to turn AUTO LSD ON and OFF
Combination Meter ABS Warning Light • Illuminates to inform the driver that a malfunction in the
ABS has occurred
• Blinks to indicate DTCs that relate to the ABS
VSC Warning Light • Illuminates to inform the driver that a malfunction in the
VSC system has occurred
• Blinks to indicate DTCs that relate to the VSC
Brake Warning light • Illuminates to inform the driver that the parking brake is
ON when the system is normal, and when the brake
fluid has decreased
• Illuminates to inform the driver that a malfunction in the
EBD has occurred
Slip Indicator Light • Blinks to inform the driver that TRC, VSC, downhill
assist control and hill-start assist control are operating
• Illuminates to inform the driver that a malfunction has
occurred in the TRC or VSC system
AUTO LSD Indicator Light*2 Lights up to inform the driver when AUTO LSD operation is
possible
Downhill Assist Control Indicator
Light*1Lights up to inform the driver when downhill assist control
operation is possible
Skid Control Buzzer • Intermittently sounds to inform the driver that the VSC is
operating
• Housed in the combination meter Components Functions

BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEMBC–25
BC
(d) While observing the screen, gently jiggle the
connector or wire harness between the ECU and
sensors, or between ECUs.
OK:
ERROR display does not change.
HINT:
The connector and/or wire harness have a
momentary interruption (open circuit) if the display
changes. Repair or replace the connector and wire
harness if either of them is faulty.
YAW RATE OPN Yaw rate sensor open detection /
ERROR or NORMALERROR: Momentary interruption
NORMAL: Normal-
DECELERAT OPN Deceleration sensor open
detection / ERROR or NORMALERROR: Momentary interruption
NORMAL: Normal-
STEERING OPN Steering angle sensor open
detection / ERROR or NORMALERROR: Momentary interruption
NORMAL: Normal-
M/C OPN Master cylinder pressure sensor
open detection / ERROR or
NORMALERROR: Momentary interruption
NORMAL: Normal- Item (Display) Measurement Item /
Range (Display)Normal Condition Diagnostic Note
C122685

BC–30BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM
BC
TEST MODE PROCEDURE
HINT:
• By switching the skid control ECU from normal mode to
test mode, abnormality detection sensitivity is enhanced
and troubleshooting can be conducted efficiently.
• Perform a sensor check in test mode after the speed
sensor or sensor rotor has been repaired or replaced.
• If the ignition switch is turned from ON to ACC or OFF
during test mode, DTCs related to the signal check
function will be erased.
• During test mode, the skid control ECU stores all DTCs
related to the signal check function, and the DTCs are
erased if normality is confirmed. Any remaining DTCs are
those indicating abnormalities that were found.
1. CHECK SENSOR SIGNAL BY TEST MODE (When
Using Intelligent Tester)
(a) Procedures for test mode:
(1) Turn the ignition switch OFF.
(2) Check that the steering wheel is in the centered
position.
(3) Check that the shift lever is in the P position and
apply the parking brake.
(4) Connect the intelligent tester (with CAN VIM) to
the DLC3.
(5) Turn the ignition switch ON.
(6) Turn the tester on.
(7) Set the intelligent tester to Test Mode (select
"Signal Check").
HINT:
Refer to the intelligent tester operator's manual
for further details.
B127989E01
C106533